Method of producing unsaturated acid from olefin

ABSTRACT

Disclosed is a shell-and-tube heat exchanger type reactor that can be used for a process of producing unsaturated acids from olefins via fixed-bed catalytic partial oxidation, which comprises at least one reaction tube, each including at least one first-step catalyst layer, in which olefins are oxidized by a first-step catalyst to mainly produce unsaturated aldehydes, and at least two second-step catalyst layers, in which the unsaturated aldehydes are oxidized by a second-step catalyst to produce unsaturated acids, wherein a first catalyst layer of the second-step catalyst layers, disposed right adjacent to the first-step catalyst layer, has an activity corresponding to 5˜30% of the activity of the catalyst layer having a highest activity among the second-step catalyst layers. A method of producing unsaturated acids from olefins by using the reactor is also disclosed.

This application is a divisional of U.S. Ser. No. 11/378,438, filed Mar.17, 2006, which claims the benefit of the filing date of Korean PatentApplication No. 2005-22723, filed on Mar. 18, 2005, in the KoreanIntellectual Property Office, the disclosure of both applications beingincorporated herein in their entirety by reference.

TECHNICAL FIELD

The present invention relates to a process of producing unsaturatedacids from olefins via fixed bed partial oxidation in a shell-and-tubeheat exchanger type reactor. Also, the present invention relates to afixed bed shell-and-tube heat exchanger-type reactor used for the aboveprocess.

BACKGROUND ART

A process of producing unsaturated acids from vapor phase C3˜C4 olefinsby using a catalyst is a typical process of catalytic vapor phaseoxidation.

Particular examples of such catalytic vapor phase oxidation include aprocess of producing acrolein and/or acrylic acid by the oxidation ofpropylene or propane, a process of producing methacrolein and/ormethacrylic acid by the oxidation of isobutylene, t-butyl alcohol ormethyl-t-butyl ether, a process of producing phthalic anhydride by theoxidation of naphthalene or orthoxylene, and a process of producingmaleic anhydride by the partial oxidation of benzene, butylene orbutadiene.

Generally, catalytic vapor phase oxidation is carried out by chargingone or more kinds of granular catalysts into a reactor tube, supplyingfeed gas into a reactor through a reaction tube, and contacting the feedgas with the catalyst in the reactor tube. Reaction heat generatedduring the reaction is removed by heat exchange with a heat transfermedium, whose temperature is maintained at a predetermined temperature.The heat transfer medium for such heat exchange is provided on the outersurface of the reaction tube so as to perform heat transfer. Thereaction mixture containing a desired product is collected and recoveredthrough a duct, and then sent to a purification step. Since thecatalytic vapor phase oxidation is a highly exothermic reaction, it isvery important to control the reaction temperature in a certain rangeand to reduce the size of the temperature peaks at hot spots generatedin reaction zones. It is also important to accomplish heat dispersion ata point to be subjected to heat accumulation due to the structure of thereactor or that of the catalyst layer.

The catalysts that may be used to perform partial oxidation of olefinsinclude composite oxides containing molybdenum and bismuth, molybdenumand vanadium, or mixtures thereof.

Generally, (meth)acrylic acid, a final product, is produced frompropylene, propane, isobutylene, t-butyl alcohol or methyl-t-butyl ether(referred to as ‘propylene or the like’, hereinafter) by a two-stepprocess of vapor phase catalytic partial oxidation. More particularly,in the first step, propylene or the like is oxidized by oxygen, inertgas for dilution, steam and a certain amount of a catalyst, so as toproduce (meth)acrolein as a main product. Then, in the second step, the(meth)acrolein is oxidized by oxygen, inert gas for dilution, steam anda certain amount of a catalyst, so as to produce (meth)acrylic acid. Thecatalyst used in the first step is a Mo—Bi-based oxidation catalyst,which oxidizes propylene or the like to produce (meth)acrolein as a mainproduct. Also, some acrolein is continuously oxidized on the samecatalyst to partially produce (meth)acrylic acid. The catalyst used inthe second step is a Mo—V-based oxidation catalyst, which mainlyoxidizes (meth)acrolein in the mixed gas containing the (meth)acroleinproduced from the first step to produce (meth)acrylic acid as a mainproduct.

A reactor for performing the aforementioned process is provided eitherin such a manner that both the two-steps can be performed in onecatalytic tube, or in such a manner that the two steps can be performedin different catalytic tubes, respectively. U.S. Pat. No. 4,256,783discloses such a reactor.

Meanwhile, (meth)acrylic acid producers have made diversified efforts toimprove the structure of the above reactor so as to increase theproduction yield of (meth)acrylic acid obtained from the reactor; topropose the most suitable catalyst to induce oxidation; or to improveoperating conditions of the process.

As a part of such prior efforts, the high space velocity or the highconcentration of propylene or the like supplied into the reactor isused. In this case, there is a problem in that oxidation occurs rapidlyin the reactor, making it difficult to control the resultant reactiontemperature. There is another problem in that hot spots are generated inthe catalyst layers of the reactor and heat accumulation occurs in thevicinities of the hot spots, so that the production of byproducts, suchas carbon monoxide, carbon dioxide and acetic acid increases at hightemperature, thereby reducing the yield of (meth)acrylic acid.

Furthermore, when (meth)acrylic acid is produced by using propylene orthe like to a high space velocity and high concentration, reactiontemperature increases abnormally in the reactor, thereby causing variousproblems, such as the loss of active ingredients from the catalystlayer, or a reduction in the number of active sites caused by thesintering of metal components, resulting in degradation in the qualityof the catalyst layer.

Accordingly, in the production of (meth)acrylic acid, control of thereaction heat in the relevant reactor is the most important to ensurehigh productivity. Particularly, both the formation of hot spots in thecatalyst layers and the heat accumulation in the vicinities of the hotspots should be inhibited, and the reactor should be effectivelycontrolled so that the hot spots do not cause the so-called runawayphenomenon of the reactor (runaway: a state in which the reactor cannotbe controlled or the reactor explodes due to a highly exothermicreaction). Therefore, it is very important to inhibit the generation ofthe hot spots and heat accumulation in the vicinities of the hot spotsso as to extend the lifetime of catalysts and to inhibit side reactions,and thus to increase the yield of (meth)acrylic acid. To achieve theseobjectives, many attempts have been steadily made.

Meanwhile, in order to operate the above processes more effectively, thereaction system should be designed in such a manner that it is suitablefor oxidation with excessive heat generation. Particularly, in order toinhibit the deactivation of a catalyst caused by excessive heatgeneration, it is necessary to establish an efficient heat controlsystem capable of controlling extremely high temperatures at hot spots,heat accumulation in the vicinities of the hot spots, and a runawayphenomenon. To provide an efficient heat control system, many studieshave been made to establish a circulation pathway of molten salts bymounting various baffles (e.g., U.S. Pat. No. 3,871,445), to design anoxidation reactor integrated with a cooling heat exchanger (e.g., U.S.Pat. No. 3,147,084), to provide a multi-stage heat control structureusing an improved heat exchanger system (e.g., Korean patent applicationNo. 10-2002-40043, and PCT/KR02/02074), and to control the structure ofa catalyst layer and the reaction temperature, so as to be suitable foran improved heat exchange system (e.g., Korean patent application No.10-2004-0069117).

DISCLOSURE OF THE INVENTION

In view of the above-mentioned problems occurring in the prior art, thepresent inventors have made improvements in a fixed-bed shell-and-tubeheat exchanger type reactor of producing unsaturated acids from olefins.An objective of the present invention is to provide a fixed-bedshell-and-tube heat exchanger-type reactor of producing unsaturatedacids from olefins, which comprises a catalyst layer with no need for alayer of inactive materials, which has been packed in the reactor priorto a catalyst layer in a second-step reaction zone, by controlling theactivity of an inlet portion of the catalyst layer of the second-stepreaction zone and/or by controlling the second-step reaction zone in amulti-stage manner.

According to an aspect of the present invention, there is provided ashell-and-tube heat exchanger type reactor that can be used for aprocess of producing unsaturated acids from olefins via fixed-bedcatalytic partial oxidation, which comprises at least one reaction tube,each including at least one first-step catalyst layer, in which olefinsare oxidized by a first-step catalyst to mainly produce unsaturatedaldehydes, and at least two second-step catalyst layers, in which theunsaturated aldehydes are oxidized by a second-step catalyst to produceunsaturated acids, wherein a first catalyst layer of the second-stepcatalyst layers, disposed right adjacent to the first-step catalystlayer, has an activity corresponding to 5˜30% of the activity of thecatalyst layer having a highest activity among the second-step catalystlayers. There is also provided a method of producing unsaturated acidsfrom olefins by using the same reactor.

As used herein, the term “activity” refers to the percent ratio of theconversion of unsaturated aldehydes into unsaturated acids in a relevantcatalyst layer, divided by the conversion in the catalyst layer havingthe highest activity under the same conditions.

Hereinafter, the present invention will be explained in more detail.

The present invention provides a shell-and-tube heat exchanger typereactor that can be used for a process of producing unsaturated acidsfrom olefins via fixed-bed catalytic partial oxidation, the reactorbeing an integrated reactor, in which a first-step reaction of mainlyproducing unsaturated aldehydes from olefins and a second-step reactionof producing unsaturated acids from the unsaturated aldehydes arecarried out sequentially in one reaction tube. The present inventionmakes an improvement in the second-step reaction zone.

(1) Catalyst Layer in Second-Step Reaction Zone

The present invention is characterized in that the first catalyst layerof at least two second-step catalyst layers, disposed right adjacent tothe first-step catalyst layer, has an activity corresponding to 5˜30% ofthe activity of the catalyst layer having the highest activity among thesecond-step catalyst layers.

In general, the inlet portion (herein, the second catalyst layer of thesecond-step catalyst layers) of the second-step reaction zone has a highconcentration of unsaturated aldehydes and oxygen, thereby causing asevere reaction. Thus, the inlet portion contributes to the totalconversion of the unsaturated aldehydes to a degree of 40% or higher.Therefore, it is preferable to control the reaction in the inlet portionof the second-step reaction zone in such a manner that the peaktemperature of the catalyst is significantly lower than the calcinationtemperature of the catalyst.

The temperature of unsaturated aldehyde-containing gas produced from thefirst-step reaction generally ranges from 300° C. to 380° C., which isthe same as the temperature of the first-step catalyst layer. Thetemperature of the second-step catalyst layer suitably ranges from 250°C. to 350° C. Therefore, the unsaturated aldehyde-containing gasproduced from the first-step reaction should be cooled so that thetemperature of the gas is adjusted to the reaction temperature of thesecond-step reaction zone. For this, an inactive layer formed ofinactive materials has been introduced between the first-step reactionzone and the second-step reaction zone according to the prior art.However, according to the present invention, a catalyst layer, which hasthe activity of the second-step catalyst but a significantly lowercatalytic activity, for example by mixing inactive materials with thesecond-step catalyst, is introduced into a reactor. By doing so, it ispossible to reduce the temperature of the unsaturatedaldehyde-containing gas produced from the first-step reaction, whiledecreasing the load of conversion of the unsaturated aldehydes in thesecond catalyst layer of the second-step catalyst layers, in whichunsaturated acids are produced to a full scale.

In other words, according to the present invention, at least twosecond-step catalyst layers are disposed right adjacent to thefirst-step catalyst layer with no use of an inactive layer, wherein thefirst catalyst layer of the second-step catalyst layers performspre-reaction of a part of the unsaturated aldehydes into unsaturatedacids, so that the second catalyst layer of the second-step catalystlayers can perform the reaction of producing unsaturated acids fromunsaturated aldehydes to a full scale under mild conditions with areduced load of conversion of unsaturated aldehydes. Particularly, thefirst catalyst layer of the second-step catalyst layers causes theunsaturated aldehyde-containing gas produced from the first-stepreaction to have a temperature and a pressure, suitable for the reactionconditions of the second catalyst layer of the second-step catalystlayers. For example, the unsaturated aldehyde-containing gas (reactionproduct of the first-step reaction) present at about 300° C. can beadapted to the reaction temperature of the second-step reaction zone,which is lower than the above temperature by about 30˜50° C., by virtueof the first catalyst layer of the second-step catalyst layers.Therefore, it is possible to prevent excessive heat generation in thesecond-step reaction zone and to extend the lifetime of the second-stepcatalyst.

Additionally, when the load of conversion of the unsaturated aldehydesin the second catalyst layer of the second-step catalyst layersdecreases, it is possible to sufficiently increase the temperature of aheat transfer medium in the shell space corresponding to the secondcatalyst layer of the second-step catalyst layers, resulting in anincrease in the conversion, and thus an increase in the yield ofunsaturated acids.

Herein, it is preferable that the first catalyst layer of thesecond-step catalyst layers shows a drop of the load of conversion ofunsaturated aldehydes (i.e., conversion of unsaturated aldehydes intounsaturated acids, caused by the first layer of the second-step catalystlayers) of 5˜30%.

Also, it is preferable that the first catalyst layer of the second-stepcatalyst layers has a catalytic activity corresponding to 5˜30% of thecatalytic activity of the catalyst layer having the highest activityamong the second-step catalyst layers, so that the aldehyde-containingmixed reaction gas introduced into the second catalyst layer of thesecond-step catalyst layers can be cooled to a temperature suitable foroxidation.

The unsaturated aldehyde-containing gas, which is a reaction productobtained from the first-step reaction zone (i.e., gas containingunsaturated aldehydes, oxygen, nitrogen, steam, unsaturated acids,acetic acid, carbon dioxide, carbon monoxide and a small amount ofbyproducts), has a temperature higher than the HTS (heat transfer salt)present at the inlet of the second-step reaction zone by 20° C. or more.Hence, the first catalyst layer of the second-step catalyst layersshould be designed so as to inhibit an excessive exothermic reaction.For this reason, it is preferable for the first catalyst layer of thesecond-step catalyst layers to have a catalytic activity correspondingto 5˜30% of the catalytic activity of the catalyst layer having thehighest activity among the second-step catalyst layer.

For example, when mixing catalyst particles with inactive materialparticles to provide the first catalyst layer of the second-stepcatalyst layers, it is possible to use the catalyst particles to anamount of 5˜30 wt %.

Methods of reducing the activity of the first catalyst layer of thesecond-step catalyst layers include: a method of mixing the samecatalytically active component as used in another catalyst layer of thesecond-step catalyst layers with inactive materials and packing theresultant mixture into the first catalyst layer; a method of forming thefirst catalyst layer by using a catalyst having a catalytically activecomponent or a composition, different from the active component or thecomposition used in another catalyst layer of the second-step catalystlayers; a method of forming the first catalyst layer by using acatalytically active material having different particle sizes orvolumes, or catalyst pellets having different particle sizes or volumes;or a method of modifying catalyst calcination temperatures. When thefirst catalyst layer of the second-step catalyst layers is mixed withinactive materials, the catalytically active component may be mixed withinactive material powder before pelletizing the catalyst. Otherwise, thepellets of inactive materials may be mixed with catalyst pellets. In thelatter case, the catalyst pellets include not only catalysts comprisingcatalytically active components alone but also supported catalystscomprising catalytically active components supported on some carriers.The shapes of such catalyst pellets include a spherical shape, hollowcylindrical shape, cylindrical shape or other particle shapes.

The inactive materials that may be used in the first catalyst layer ofthe second-step catalyst layers include alumina, silica alumina,stainless steel, iron, steatite, porcelain and various ceramic products.The pellets of such inactive materials may take the form of spheres,cylinders, rings, rods, plates, iron nets and agglomerates with asuitable size. If desired, inactive materials having different forms maybe used in combination at an adequate mixing ratio.

Meanwhile, the first catalyst layer of the second-step catalyst layerspreferably has a length corresponding to 5˜50% of the length of thereaction tube of the second-step reaction zone.

The first catalyst layer of the second-step catalyst layers is the layerhaving a reduced catalytic activity so as to prevent degradation in thethermal stability caused by an excessive reaction heat, which isgenerated by chemical reactions in the catalyst layer. However, it ispreferable for the first catalyst layer to provide a conversion ratio ofreactants to a degree of 5% or more, in order to ensure the effect ofstabilizing the temperature in the second catalyst layer of thesecond-step catalyst layers. The length of the first catalyst layerdepends on the activity of the corresponding catalyst. In order toprovide a conversion ratio of about 5% by the first catalyst layer,based on the total conversion ratio of the second-step reaction, thefirst catalyst layer should have a length corresponding to at least 5%of the length of the reaction tube of the second-step reaction zone,with the proviso that the first catalyst layer has an activity asdisclosed herein. However, when the length of the first catalyst layeris too long relative to the total length of the second-step catalystlayer, the overall activity of the total catalyst layer decreases, whichmay result in a significant decrease in conversion ratio. Therefore, itis preferable that the first catalyst layer of the second-step catalystlayers is less than 50% of the length of the second-step reaction zone.In other words, high-activity catalyst layers of the second-stepcatalyst layers, except the first catalyst layer, should be provided toa proportion of at least 50%, so as to obtain a conversion ratio of atleast 95%. As described above, the catalyst layer according to thepresent invention avoids a need for an inactive layer for coolingbetween the first-step reaction zone and the second-step reaction zone,and makes it possible to reduce the length of the catalytic reactiontube. Therefore, the reactor according to the present invention is verycost-efficient.

(2) Partition for Dividing First-Step Reaction Zone from Second-StepReaction Zone, and Placement of First Catalyst Layer of Second-StepCatalyst Layers

The composition, temperature and pressure of feed mixture to thesecond-step reaction zone, namely, those of a resultant product in thefirst-step reaction zone in which unsaturated aldehydes are mainlyproduced from olefins, depend on those of feed mixture to the first-stepreaction zone. Hence, it is preferable to change the temperaturecondition of a heat transfer medium in the second-step reaction zone inorder to establish new optimal process conditions flexibly depending onvariations in the external environment and feed mixture conditions.

According to another aspect of the present invention, the shell space ofthe reactor is divided axially by using a partition into two shellspaces, wherein one of the shell spaces mainly comprises the first-stepreaction zone and the other of the shell spaces comprises thesecond-step reaction zone. Herein, the first catalyst layer of thesecond-step catalyst layers, corresponding to the inlet portion of thesecond-step reaction zone, is packed into the reaction tube in such amanner that it includes the whole sections of the partition, by whichthe shell space of the first-step reaction zone is divided from that ofthe second-step reaction zone. Considering the cost needed for theconstruction of the reactor, it is preferable for the first catalystlayer of the second-step catalyst layers to occupy the first-stepreaction zone by at most 500 mm. Retention time corresponding to about500 mm may reduce the load of conversion of unsaturated aldehydes toabout 10%. When the first catalyst layer of the second-step catalystlayers, which has a low catalytic activity according to the presentinvention, is disposed in the reaction tube at a position correspondingto the portion having the partition, by which the shell space of thefirst-step reaction zone is divided from that of the second-stepreaction zone, it is possible to prevent a local temperature increasecaused by an incomplete heat transfer at the portion having thepartition.

(3) Multi-stage Heat Control for Second-Step Reaction Zone

According to the present invention, the catalyst layer is formed with nouse of a cooling layer that has been packed into the reactor prior tothe catalyst layer of the second-step reaction zone. For this reason, itis preferable to perform the heat control of the second-step reactionzone in a multi-stage manner, besides controlling the catalytic activityof the first catalyst layer of the second-step reaction zone. To performsuch multi-stage heat control, it is preferable to further divide theshell corresponding to the second-step reaction zone into at least twoshell spaces by using partitions, and to set the temperature of the heattransfer medium supplied to each shell space in an independent manner.

By doing so, it is possible to set an optimal temperature depending onthe activity of the catalyst packed into the reaction tube of therelevant shell, and thus to increase the yield. Also, it is possible toinhibit heat accumulation at a hot spot and to prevent a so-calledrunaway phenomenon by virtue of the aforementioned multi-stage heatcontrol.

It is preferable to set the temperature of the heat transfer medium insuch a manner that the temperature of the reaction mixture at thebeginning of the first catalyst layer of the second-step catalyst layersis higher than the temperature of the heat transfer medium circulatingin the first shell space of the second-step reaction zone by 20˜70° C.This makes it possible to inhibit an excessive exothermic reaction andto provide a sufficient catalytic activity. On the other hand, it ispreferable to set the temperature of the heat transfer media of thesubsequent shell spaces high enough to increase the conversion of theunsaturated aldehyde as high as possible.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram showing the structure of a pilot reactorhaving one reaction tube, and the structure of a catalyst layer insidethe reaction tube, wherein both the first-step reaction and thesecond-step reaction are carried out in one reactor according to Example1 of the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

Reference will now be made in detail to the preferred embodiments of thepresent invention. It is to be understood that the following examplesare illustrative only and the present invention is not limited thereto.

EXAMPLE 1 Use of Mixed Catalyst Layer and Multi-stage Heat Control

The following experiment was carried out in a pilot reactor having onereaction tube, in which both the first-step reaction and the second-stepreaction are performed. The reaction tube had an inner diameter of 26mm. The first-step catalyst layer and the second-step catalyst layerwere packed into the reaction tube to a height of about 3570 mm andabout 3125 mm, respectively. The catalyst packed into the first-stepreaction zone was a first-step oxidation catalyst based on molybdenum(Mo) and bismuth (bi). Preparation of the catalyst is disclosed inKorean Patent No. 0349602 (Korean Patent Application No.10-1997-0045132). Each of the three catalyst layers packed into thesecond-step reaction zone was comprised of a second-step oxidationcatalyst based on molybdenum (Mo) and vanadium (V). Preparation of thecatalyst is disclosed in Korean Patent No. 0204728 or 0204729.

The second-step catalyst layers were formed by using three catalystlayers that have different activities, increasing when viewed from theinlet to the outlet (see U.S. Pat. Nos. 3,801,634 and 4,837,360: Controlof Catalytic Activity). The first catalyst layer of the second-stepcatalyst layers, which was the inlet portion of the second-step reactionzone, was comprised of a mixture of 20 wt % of the same catalyticsubstance as used in the third catalyst layer of the second-stepcatalyst layers and 80 wt % of an inactive material. Therefore, thefirst catalyst layer had an activity corresponding to about 20% of theactivity of the third catalyst layer. The second catalyst layer of thesecond-step catalyst layers had an activity corresponding to about 87%based on the activity of the third catalyst layer.

The three catalyst layers of the second-step reaction zone had a heightof 500 mm, 700 mm and 1925 mm, respectively, along the axial direction.The mixed layer as the first catalyst layer of the second-step catalystlayers was packed into the reaction tube corresponding to the shellspace of the second-step reaction zone to a height of 250 mm, and theremaining height (250 mm) of the first catalyst layer was packed in sucha manner that the remaining part covered the partition (partition fordividing the first-step reaction zone from the second-step reactionzone) and some part of the shell space of the first-step reaction zone.

The second-step reaction zone was divided into two independent shellspaces by a partition disposed at the border between the second catalystlayer and the third catalyst layer. Each of the molten salts filled intoeach of the shell spaces was individually set at a temperature of 275°C. and 270° C.

Starting materials injected into the second-step reaction zone (at theposition of the partition for dividing the first-step reaction zone fromthe second-step reaction zone) included acrolein, acrylic acid, oxygen,steam and nitrogen gas. More particularly, the starting materialsincluded 5.5% of acrolein, 0.9% of acrylic acid, 5.0% of oxygen, 1.0% ofbyproducts including CO_(x) and acetic acid, and the remaining amount ofnitrogen gas. The space velocity in the second-step reaction zone was1500 hr⁻¹ (standard temperature and pressure, STP). Herein, the spacevelocity of acrolein as a hydrocarbon reactant supplied to thesecond-step reaction zone had a space velocity of 81 hr⁻¹ (STP) and themixed feed gas had a pressure of 0.4 kgf/cm²G.

In the second-step reaction zone, two catalyst layers except the firstcatalyst layer (mixed layer) showed temperature peaks at a temperatureof 309.4° C. and 321.7° C. along the axial direction. When propylene wasintroduced into the first-step reaction zone to an amount of 7.0%, yieldof acrylic acid was 86.2%. Yields of byproducts, i.e., CO_(x) (carbonmonoxide and carbon dioxide) and acetic acid were 8.51% and 1.80%,respectively.

The reaction mixture that reached the first catalyst layer of thesecond-step catalyst layers along the axial direction showed atemperature of 316° C., which was different from the temperature of thefirst heat transfer medium of the second-step reaction zone by 41° C.

COMPARATIVE EXAMPLE 1 Experiment with No Use of Mixed Layer andMulti-stage Heat Control

The shell space of the second-step reaction zone was a singlenon-divided shell space. Additionally, a cooling layer formed ofinactive particles was disposed between the first-step reaction zone andthe second-step reaction zone. The cooling layer was packed into thereactor to a height of 500 mm. More particularly, the cooling layer waspacked into the second-step reaction zone to a height of 250 mm, and theremaining part of the cooling layer was packed into the reaction tuberanging from the partition to the first-step reaction zone. Thesecond-step catalyst layers included two different kinds of catalysts,which were the same as used in the second catalyst layer and the thirdcatalyst layer of Example 1, respectively. Both catalyst layers werepacked to a height of 700 mm and 2000 mm along the axial direction. Theheat transfer medium was set at a temperature of 270° C. under anisothermal condition. Except the foregoing, the experiment was carriedout in the same manner as described in Example 1. Additionally, the twokinds of catalysts, which were used in Example 1, were used in thisExample to the same total amount.

In the second-step reaction zone, two catalyst layers showed temperaturepeaks at a temperature of 318.2° C. and 305.2° C. along the axialdirection. Yield of acrylic acid was 84.4%. Yields of byproducts, i.e.,CO_(x) (carbon monoxide and carbon dioxide) and acetic acid were 10.4%and 2.03%, respectively.

COMPARATIVE EXAMPLE 2 Experiment with No Use of Mixed Layer andMulti-stage Heat Control

Comparative Example 1 was repeated, except that the heat transfer mediumwas set at a temperature of 275° C.

In the second-step reaction zone, two catalyst layers showed temperaturepeaks at a temperature of 325.1° C. and 324.9° C. along the axialdirection. Yield of acrylic acid was 82.9%. Yields of byproducts, i.e.,CO_(x) (carbon monoxide and carbon dioxide) and acetic acid were 11.4%and 2.42%, respectively.

<Discussion>

It can be seen from the above results of Example 1 and ComparativeExamples 1 and 2 that Example 1 provides a higher yield of acrylic acid,compared to the other Examples by about 2% or more, and shows the firstpeak at a significantly stable temperature. Yield of acrylic acidrelates directly to the productivity, and thus is very important.Additionally, the first peak temperature is important because it relatesto the lifetime of the catalyst. Reactions carried out in the secondcatalyst layer of the second-step reaction zone according to Example 1and the first catalyst layer of the second-step reaction zone accordingto Comparative Examples 1 and 2 contribute the total acrolein conversionby 50% or more. Although the above catalyst layers are relatively short,they provide a relatively high conversion. In these layers, thecompositions of acrolein and oxygen are high, resulting in a severereaction. Thus, in these layers, it is preferable to control thereactions in such a manner that the peak temperature of the catalyst issignificantly lower than the calcination temperature of the catalyst.According to Example 1, the peak temperature is 309.4° C. This indicatesthat the reaction is carried out at a temperature significantly lowerthan the reaction temperatures in Comparative Examples 1 and 2 (318.2°C. and 325.1° C.). Therefore, because the reaction is carried out at theinlet portion of the catalyst layers, having a high conversion load,under a milder condition, it is possible to extend the lifetime of thecatalyst.

Additionally, Example 1 uses a mixed layer comprising a diluted catalystin the inlet portion, and thus permits a pre-reaction in a catalystlayer having a significantly lower catalytic activity. Hence, it ispossible to reduce the load of conversion of acrolein into acrylic acidin the second catalyst layer to a certain degree. Because a part ofacrolein is preliminarily converted into acrylic acid under a mildcondition provided by the diluted mixed catalyst layer, the secondcatalyst layer can have a significantly lower load of conversion ofacrolein, compared to the loads of Comparative Examples 1 and 2 with nouse of a mixed layer. Also, it is possible to obtain a higher conversionby increasing the temperature of the heat transfer medium in the firstshell space along the axial direction, resulting in an increase in theyield of acrylic acid. In Example 1, the first heat transfer medium hasa temperature of 275° C., which is higher than the correspondingtemperature of Comparative Example 1 by 5° C. However, the peaktemperature of the catalyst layer according to Example 1 is lower thanthe corresponding temperature of Comparative Example 1 by about 9° C.This is because the mixed layer allows the reaction to be performedpartially.

In Comparative Example 2, the temperature of the heat transfer medium inthe shell space of the second-step reaction zone is same as thecorresponding temperature of the first shell space of the second-stepreaction zone in Example 1 (275° C.). However, due to the lack of themixed layer in the inlet portion, acrolein reacts severely with oxygenunder a high concentration, so that the peak temperature increases to325.1° C. Such reaction performed at a high temperature may result in adrop in the lifetime of the first catalyst layer having a high load ofconversion.

Industrial Applicability

As described above, according to the present invention, there isprovided a structure of catalyst layers, a heat control system and aprocessing condition, adequate to an improved reactor for producingunsaturated acids via two-step oxidation of olefins. Thus, it ispossible to obtain a final product in a stable manner even under a highload reaction conditions. Additionally, use of the heat control systemprevents the generation of a hot spot or inhibits heat accumulation atthe hot spot. Therefore, it is possible to obtain a high productivity ofunsaturated acids and to extend the lifetime of a catalyst.

1. A shell-and-tube heat exchange reactor for producing unsaturatedacids from olefins, the reactor comprising: at least one reaction tube;at least one shell; at least one first-step catalyst layer disposed ineach reaction tube, wherein the first-step catalyst layer comprises acomposite oxide which comprises molybdenum and bismuth, and whichcatalyzes the oxidation of olefins to produce unsaturated aldehydes; andat least two second-step catalyst layers disposed in each reaction tube,wherein each second-step catalyst layer comprises a composite oxidewhich comprises molybdenum and vanadium, and which catalyzes theoxidation of the unsaturated aldehydes to produce unsaturated acids,wherein a first catalyst layer of the at least two second- step catalystlayers is disposed directly adjacent to the at least one first-stepcatalyst layer, and the first catalyst layer of the at least twosecond-step catalyst layers has an activity of 5 to 30 percent of anactivity among the at least two second-step catalyst layers, wherein thereactor further comprises a shell space, wherein the shell space isdefined by the at least one reaction tube and the at least one shell,the shell space is divided axially by a first partition into at leasttwo shells space portions, wherein a first shell space portion of the atleast two shell space portions comprises a first portion correspondingto a first-step reaction zone which comprises the at least one firststep catalyst layer, and a second shell space portion of the at leasttwo shell space portions comprises a second portion corresponding to asecond-step reaction zone which comprises a second catalyst layer of theat least two second-step catalyst layers, and the first catalyst layerof the at least two second-step catalyst layers is disposed in a portionof the at least one reaction tube which overlaps an entirety of across-section of the first partition.
 2. The shell-and-tube heatexchange reactor of claim 1, wherein the first catalyst layer of the atleast two second-step catalyst layers provides a drop in a load ofconversion of unsaturated aldehydes of 5 to 30 percent.
 3. Theshell-and-tube heat exchange reactor of claim 1, wherein the firstcatalyst layer of the at least two second-step catalyst layers occupiesthe first-step reaction zone by at most 500 millimeters.
 4. Theshell-and-tube heat exchange reactor of claim 1, wherein the secondshell space portion is divided into at least a third shell space portionand a fourth shell space portion by at least one second partition,wherein each shell space portion comprises a heat transfer medium, andeach heat transfer medium is configured to be independently set at adifferent temperature.
 5. The shell-and-tube heat exchange reactor ofclaim 4, wherein a temperature of a reaction mixture at a beginning ofthe first catalyst layer of the at least two second-step catalyst layersis 20 to 70° C. higher than a temperature of a heat transfer mediumcirculating in the third shell space of the second-step reaction zone.6. The shell-and-tube heat exchange reactor of claim 1, wherein thefirst catalyst layer of the at least two second-step catalyst layers hasa length which is 5 to 50 percent of a length of the reaction tube ofthe second-step reaction zone.
 7. The shell-and-tube heat exchangereactor of claim 1, wherein the first catalyst layer of the at least twosecond-step catalyst layers comprises a catalyst particle and aninactive material particle.
 8. The shell-and-tube heat exchange reactorof claim 1, wherein the first catalyst layer of the at least twosecond-step catalyst layers comprises a plurality of pellets, eachpellet comprising a catalyst particle and an inactive material particle.9. The shell-and-tube heat exchange reactor of claim 1, wherein thesecond-step reaction zone is divided by the second partition into atleast two shell spaces.